Assembly

1. Install viscous clutch, drive sprocket, drive sprocket spacer and sun gear shaft bearing onto sun gear shaft.

2. Using tool Nos. J-7079 and J-38212, or equivalents, install input shaft pilot bearing into output shaft assembly.

3. Install output shaft assembly to gear ring.






4. Install gear ring snap ring to gear ring.

5. Install output shaft bearing and bearing snap ring to front cover.






6. Using tool Nos. J-7079 and J-38212, or equivalents, install output shaft rear bearing to rear case half.






7. Install output shaft rear bearing snap ring.

8. Apply Loctite 51580, or equivalent, to rear case half extension housing sealing surface.

9. Position extension housing to rear case, then install extension housing retaining bolts. Torque retaining bolts to 35 ft. lbs.

10. Install speed sensor and speed sensor retaining bolt. Torque retaining bolt to 10 in. lbs.









11. Using tool Nos. J-37668, or equivalent, install output shaft oil seal to extension housing. Align water drain hole in oil seal with drain groove in extension housing.

12. Install planetary carrier assembly thrust washer to output shaft assembly and align with input shaft pilot bearing.

13. Install planetary carrier assembly into gear ring.






14. Install sun gear shaft assembly into planetary carrier assembly, aligning viscous clutch teeth to gear ring spline.

15. Install input shaft into input shaft pilot bearing, aligning input shaft with sun gear shaft thrust washer and planetary carrier assembly thrust washer.

16. Install driven sprocket onto front output shaft.

17. Install drive chain onto driven sprocket.






18. Install drive chain over drive sprocket and front output shaft into output shaft rear bearing.

19. Install front output shaft spacer on front output shaft.

20. Install magnet to rear case half, then apply Loctite 51580, or equivalent, to rear case half front cover sealing surface.

21. Install front cover and front cover retaining bolts to rear case half. Torque retaining bolts to 35 ft. lbs.

22. Using tool No. J-37668, or equivalent, install front output shaft oil seal to front cover.

23. Using tool No. J-38216, or equivalent, install input shaft oil seal.






24. Install front output flange to front output shaft.






25. Install rubber sealing washer, steel flat washer and new front output flange nut. Torque flange nut to 80 ft. lbs.